Objective

Increasingly stringent emission and fuel economy standards have been pushing old combustion engines into an accelerated evolution phase. In this context, OEMs in the industry have shifted their R&D efforts towards more thermally efficient, less polluting and down-sized engines, thus viewing the production of low emission and fuel consumption vehicles. The concept of VCR engines (i.e. the compression ratio (CR) of the internal combustion engine can be modified under dynamic driving conditions and performance needs) has been considered as an essential future technology to meet these targets. However limitations associated with their effect in engine’s architecture, their impact on the reduction of CO2 emissions and additional productions costs have hindered their widespread commercial application.Our ground-breaking VCR system will be the first able to address the burning needs of the industry. Gomecsys VCR system is a highly innovative system differentiated from alternatives due to its engineering simplicity able to significantly enhance the performance of conventional combustion engines achieving a staggering 5-10% reduction on fuel consumption and CO2 emissions. Our core aim is to commercialize the 6th generation of our VCR system in 2020 and its commercial viability will be based on our ability to define business opportunities in target markets and attract key partners and customer OEMs for our project. Moreover, we are convinced that our project will provide “resource efficient transport that respects the environment” which is considered a critical aspect to meet “Smart, Green and Integrated Transport” societal challenge addressed by Horizon 2020 programme.Finally, through the completion of Gomecsys VCR system project we expect to reach €15 million revenues five years after its commercialization. Phase 2 will require a €2 million investment, which will present a Cumulative Return of Investment of 4.99 in 2024.

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One crankshaft for every engine, energy efficiency for all

Original equipment manufacturers (OEMs) are reworking old combustion engines to meet ever-more stringent emission and fuel economy standards. Contributing to these efforts, an EU-funded team has driven research towards the design of a groundbreaking variable compression ratio (VCR) engine.

With an eye on producing low emission and fuel consumption vehicles, related R&D efforts are directed at engines that are smaller in size, more thermally efficient and less polluting. In the VCR concept, the internal combustion engine’s compression ratio can be modified under dynamic driving conditions and performance needs. However, the impact on engine architecture, CO2 emissions reduction and additional production costs remain obstacles to widespread commercial application.
The project GOMECSYS VCR system targeted the reduction of fuel consumption and CO2 emissions in motor vehicles through a highly innovative system based on engineering simplicity. The core goal, explains Mr Bert de Gooijer, project coordinator, was to “realise a reduction of CO2 emissions from combustion engines of 8 % by just replacing the original crankshaft with a Gomecsys VCR crankshaft.” The team achieved that and more.
One engine part overhaul, infinite possibilities
Project efforts have delivered plus marks in two crucial areas: system features and industrial application. Specifics for each category are available on the dedicated web page, but the crux is this: “The main advantage of the Gomecsys VCR technology is that the complete VCR system is integrated on the crankshaft.”
What’s the overriding benefit of this ease of integration? “No modifications to the original engine architecture are needed to upgrade any existing engine to a VCR engine,” explains Mr de Gooijer. Just by replacing the crankshaft, all engine types – from a 1-cylinder to a V8 – can be upgraded. This saves OEMs from additional costs for new engine parts, and also translates to fast time-to-market.
The system supports fully variable and fast, closed loop, actuation of the VCR position. Other advantages are that it is a true 4-stroke cycle and has no additional friction. It is also economical, boasting low additional production cost at just EUR 20 per gram of CO2 reduction.
Full-speed ahead to fuel and emissions savings
One of the project’s two most important outcomes is a proven result of 8 % CO2 reduction. The second is a demo car with no audible gear noise that has also demonstrated torque and power. In general, VCR technology has good synergy when used in an Atkinson/Miller cycle engine, and is well suited for upgrading 1-cylinder engines used in the global 2-wheeler market.
A new path to resource-efficient transport
Another core project aim was to boost efforts focused on commercialising its 6th generation VCR system, defining business opportunities in target markets and attracting key partners and customer OEMs. “To bring about more awareness we have hired local agents to introduce the Gomecsys VCR technology to car manufacturers,” Mr de Gooijer notes. “The result is that we have established eight new contacts with major car manufacturers around the world.”
R&D work continues with several manufacturers, and the system shows high potential to fulfil resource-efficient transport goals.